text:
|Publication number
|Publication type
|Application number
|Publication date
|Mar 5, 1996
|Filing date
|Sep 10, 1993
|Priority date
|Jun 6, 1988
|Fee status
|Also published as
|Publication number
|Benzion Landa
|Original Assignee
|Indigo N.V.
|Export Citation
|BiBTeX, EndNote, RefMan
|Patent Citations (66), Referenced by (3), Classifications (7), Legal Events (6)
|External Links: USPTO, USPTO Assignment, Espacenet
This application is a continuation of application Ser. NO. 07/202,687, filed Jun. 6, 1988, now U.S. Pat. No. 5,270,776.
The present invention relates generally to an electrostatic imaging process employing liquid toner, including an improvement in the method of applying heat to the developed image while fusing and fixing.
In known processes of electrostatic imaging, a image may be recorded in the form of an electrostatic latent image upon a photoconductive member. A developed image may then be obtained from the latent image by application of toner particles, which may be in the form of a finely powdered solid or a liquid dispersion.
In the electrostatic imaging process employing liquid toner, the basic steps are:
1. Generating an electrostatic latent image, e.g. on a photoconductive surface such as a plate or drum which has been sensitized by charging with a corona discharge and by exposure to light in the form of an image of an object--the charge is dissipated in exposed areas;
2. Developing the latent image by contact with a liquid dispersion ("toner") of fine particles which in a positive process are attracted to the charged areas and which in a reverse process are attracted to the uncharged areas;
3. Removal of excess liquid toner and particles from the background areas;
4. Transfer of the image, e.g. to a substrate such as paper, under influence of an electrical field; ,
5. Fixing the image by fusing the particles together and to the substrate; and
6. Cleaning the plate or drum for reuse.
In this connection reference is made to the following issued U.S. patents in the field of electrophotography: U. S. Pat. Nos. 3,990,696, 4,233,381, 4,253,656, 4,256,820, 4,269,504, 4,278,884, 4,286,039, 4,302,093, 4,326,644, 4,326,792, 4,334,762, 4,350,333, 4,355,883, 4,362,297, 4,364,460, 4,364,657, 4,364,661, 4,368,881, 4,378,422, 4,392,742, 4,396,187, 4,400,079, 4,411,976, 4,412,383, 4,413,048, 4,418,903, 4,420,244, 4,435,068, 4,439,035, 4,454,215, 4,460,667, 4,473,865, 4,480,825, 4,501,486, 4,522,484, 4,531,824, 4,538,899, 4,582,774, 4,585,329, 4,586,810, 4,589,761, 4,598,992, 4,603,766, 4,620,699, 4,627,705 and 4,678,317, the disclosures of all of which are incorporated by reference herein.
Following development, the excess liquid toner and particles are removed from the image, by a step often referred to as "metering". This step may be carried out by use of an electrically biased reverse roller which also shears off the "fluffy" part of the imaged regions. At the transfer stage, there is likely to occur a degree of smudging, smearing or squashing of the image, which detracts from its quality.
In published UK patent application GB 2169416A (Landa et al), the disclosure of which is incorporated herein by reference a degree of squash-resistance is imparted to the developed image by using fibrous toner particles which may be prepared as follows: a thermoplastic polymer (and pigment) is plasticized with a nonpolar liquid, preferably at elevated temperature, to form a sponge, the sponge is shredded, more nonpolar liquid is added, the pieces of shredded sponge are wet-ground into particles and the grinding is continued to pull the particles apart to form fibers extending therefrom (the particles preferably having a diameter less than 5 microns). Finally, a charge director may be added to impart a charge of predetermined polarity to the toner particles.
In an alternative method of preparation which is also the subject of published UK patent application GB 2176904A (Landa et al), the disclosure of which is incorporated herein by reference, a thermoplastic polymer is plasticized at an elevated temperature with a nonpolar liquid, a pigment is stirred into the plasticized polymer to disperse it therein, stirring is continued to prevent the formation of a sponge while reducing the viscosity of the mixture by adding additional nonpolar liquid to form a dispersion, cooling while continuing stirring to permit the precipitation of pigmented polymer (toner) particles having a plurality of fibers and withdrawing the dispersion having a concentration of toner particles from the mixing step. Charge director may be added as before.
It is self-evident that the principal difference between the content of the toner image formed with dry toner and that formed with liquid toner, is that the toner image formed with liquid toner contains the solvent, usually a hydrocarbon solvent, in which the toner particles are suspended, this solvent being absent from the image formed using dry toner. In order to produce a visible image when using a liquid toner, which resembles the image obtained when using a solid toner, the prior art which relates to fusing and fixing a developed image by the application of heat thereto assumes the simultaneous removal by evaporation of the toner solvent.
Thus, in U.S. Pat. No. 4,474,456 (Kobayashi et al), which relates to a heat-fixing device including a heat plate along which a transfer medium bearing thereon a toner image is advanced during which the toner image becomes fixed to the transfer medium by fusing, it is stated that in an electrophotographic copying machine of the wet-development type, a sufficient amount of thermal energy must be applied to the transfer medium to remove the carrier liquid impregnated into the transfer medium by evaporation.
Published European Patent Application 0247248A1 discloses a process in which an electrostatic charge pattern is developed with liquid toner and the developed image is fixed by the simultaneous application of heat and pressure, characterized by the fact that the toner particles have a particular melt viscosity in the dry state. The disclosure contemplates evaporation during fixing of a substantial part of the carrier liquid, removal of the vapors thus produced by suction or by pressurized entrainer gas, and disposal of the removed vapors by adsorption or absorption, condensation or combustion.
Published European Patent Application 0244198A2 describes and claims a reproducing machine (and a corresponding method) including apparatus for applying heat to sheet material having a liquid-developed image thereon to remove substantially all of the liquid carrier transferred thereto so as to dry the sheet of support material and at least partially melt the pigmented particles transferred thereto, as well as apparatus for generating heat to the pigmented particles so as to fuse them to the support in image configuration.
U.S. Pat. No. 4,727,394 (Bov et al) claims a reproducing machine incorporating a hot fusing roll cooperating with a pressure roll to apply heat and pressure to a developed image on a sheet of support material so as to vaporize substantially all of the liquid carrier transferred thereto and to substantially permanently fuse the pigmented particles to the sheet of support material.
The disadvantage of these prior art methods is that removal of organic solvent from the developed image as recited therein creates a pollution problem in the immediate environment, which must be countered, if-pollution is to be avoided, by taking special measures as set out in above-mentioned published European Patent Application 0247248A1, namely by adsorption or absorption, condensation or combustion.
It is a principal object of the present invention to avoid the pollution problem just mentioned, in an electroimaging process utilizing liquid toner.
Another object of the invention is to avoid the additional cost and inconvenience of having to absorb, condense or burn off the organic solvent vapors, in the above-mentioned prior art processes.
Yet another object of the invention is to employ a step of fusing a fixing a liquid-developed image in an electrostatic imaging process, by the employment of heat, while nevertheless avoiding the disadvantages mentioned in relation to the prior art described above. Other objects of the invention will become apparent as the description proceeds.
There is thus provided in accordance with a preferred embodiment of the present invention in an imaging process which includes the steps of developing an image with liquid toner including a liquid carrier, fusing and fixing the image by the application of energy thereto, the improvement including preselecting at least the energy applied upon fusing and fixing and the properties of the liquid carrier, such that the liquid carrier is not substantially removed upon fixing and fusing.
Preferably a major part of the liquid carrier is not removed upon fixing and fusing. In a preferred embodiment, at least 50% by weight of the liquid carrier is not evaporated upon fixing and fusing.
In accordance with a preferred embodiment of the present invention there is provided in an electrostatic imaging process which comprises the steps of developing an electrostatic image with liquid toner including at least pigmented thermoplastic polymer particles and a liquid carrier, transferring the developed image to a substrate and subsequently fusing and fixing the substrate-supported developed image by the application of heat from the surface of an elastomer-coated first roller thereto, said surface being lubricated and said substrate being transported through a nip defined by a portion of the surface of said first roller and a portion of the surface of a second elastomer-coated roller located on the reverse side of the substrate, the improvement comprising pre-selecting at least the following conditions, namely, the temperature at which the fusing and fixing is effected, the rate of transport of the substrate, and the properties of the liquid carrier, such that the liquid carrier is not all substantially removed from the substrate-supported image.
The present invention will be understood and appreciated mope fully from the following detailed description taken in conjunction with the drawings, in which:
FIG. 1 is a schematic illustration of electrostatic imaging apparatus, which may be employed for effecting the process of the invention in accordance with a particular embodiment thereof;
FIG. 2 is a more detailed schematic illustration of apparatus for fusing and fixing a developed image onto a carrier sheet, useful in the apparatus of FIG. 1; and
FIG. 3 is a schematic illustration of a detail of electrostatic imaging apparatus, which may be employed for effecting the process of the invention in accordance with an alternative embodiment thereof.
Reference is made to FIG. 1 in which there is shown electrostatic imaging apparatus employing a liquid toner. The apparatus includes a metal drum 2 which carries a photoconductor 4 and which is mounted by disks 6 onto a shaft 8. The disks are secured to shaft 8 by a key 10 so that the shown drum assembly, which is provided in a light-proof housing (not shown), is operative to rotate with shaft 8.
Shaft 8 is driven in any appropriate manner (not shown) in the direction of arrow 9 past a corona discharge device operative to charge the surface of photoconductor 4. The image to be reproduced is projected onto the charged photoconductor by an optical system 14. Since shaft 8 is grounded at 15 and disks 6 are conductive, the areas struck by light conduct the charge, or a portion thereof, to ground, thus forming on the photoconductor an electrostatic latent image.
The liquid toner is circulated from any suitable source (not shown) through a pipe 16 into a development tray 18 from which it is drawn through a pipe 20 for recirculation. Development electrodes 22, which may be appropriately biased as known to the art, assist in toning the electrostatic latent image as it passes into contact with the toner.
As the amount of liquid on the photoconductor surface is normally too great for satisfactory subsequent transfer of the developed image, a roller 24, whose surface moves in a direction opposite to that of the photoconductor surface, is spaced from the photoconductor surface and is operative to shear excess liquid from the developed image without disturbing it. An exemplary roller is shown in U.S. Pat. No. 3,907,423, the disclosure of which is incorporated herein by reference.
Roller 24 is driven, typically by a drive belt 26 which is in turn driven by any appropriate, known speed-controllable motor means (not shown). The roller is kept clean by a wiper blade 28.
A pair of register rollers 32 and 34 is operative to feed to a transfer station, referenced generally 44, a carrier sheet 100, which is to receive the developed image. At transfer station 44, a corona discharge device 46 is operative to impress upon the rear of the carrier sheet a charge of polarity opposite to that of the toner particles forming the developed image. The developed image is thus drawn towards the carrier sheet.
Rollers 32 and 34 are mounted onto and secured for rotation with respective axles 36 and 38. The axles are driven in synchronism so that there is no relative motion between the points of closest approach of the rollers 32 and 34 to each other. Alternatively, if desired, only one of the register rollers need be driven.
A pick-off member 48 assists in the removal from the photoconductor of the carrier sheet bearing the developed image. A roller 50 coacting with a plurality of flexible bands 52 mounted onto a plurality of rollers 54 delivers the carrier sheet to fusing and fixing apparatus, referenced generally 64. Apparatus 64 is described below in greater detail in conjunction with FIG. 2.
A cleaning roller 56, formed of an appropriate synthetic resin as known in the art, is driven in a direction opposite to that of photoconductor 4, so as to scrub clean the surface thereof. To assist in this action, insulating, nonpolar, nontoxic liquid may be fed through a pipe 58 to the surface of the cleaning roller 56. A wiper blade 60 completes the cleaning of the photoconductive surface. Any residual charge left on the photoconductive drum is extinguished by flooding the photoconductor surface with light from a lamp 62.
Reference is now made to FIG. 2 in which there is shown fusing and fixing apparatus, constructed and operative in accordance with a preferred embodiment of the invention. Carrier sheet 100 is fed in the direction of an arrow 66 and, with the assistance of a guide member 99, between a heated roller 68 and a pressure roller 70.
In the shown embodiment, roller 68 is driven by any suitable means (not shown) and, as it rotates in a direction shown by arrow 72, it is also operative to cause rotation of roller 70 by friction. Roller 68 typically comprises a hollow metal cylindrical core in which is provided a heat source 69 which helps in fusing the developed image borne by the carrier sheet as it is drawn between rollers 68 and 70.
The metal core of roller 68 is coated with a thin layer 71 of a synthetic elastomer material having a hardness value of not greater than about 50 on the Shore A scale. A typical synthetic material is silicone rubber. It is preferred that the composition of the synthetic material of which layer 71 is formed is such that the occurrence of offset of a developed image coming into contact with the layer is negligible.
Roller 70 comprises a cylindrical metal core 74 onto which there is mounted a sleeve 76 of a synthetic elastomer material having a hardness value of not greater than about 50 on the Shore A scale. A typical synthetic material is silicone rubber. The hardness of the material of sleeve 76 may be less than that of the material of layer 71; alternatively or additionally, the ratio of the thickness of layer 71 to thickness of sleeve 76 may be less than 1, and is preferably in the less than 1 to 10. For example, layer 71 may be 0.4 mm thick and sleeve 76 may be 20 mm thick.
Due to the difference in respective thicknesses of layer 71 and sleeve 76, roller 68 is much less resilient than roller 70. Consequently, when roller 68 presses against roller 70 along an axis 77, the surface of roller 70 becomes indented and a continuous contact length or `nip` is formed between the rollers and between two points indicated by arrows A and B.
It may be appreciated that as the carrier sheet is drawn into the nip, it is of great importance in ensuring that effective fusing and fixing of the image on the sheet takes place without the image being squashed, smeared or smudged. There is provided, therefore, apparatus for adjusting the pressure between rollers 68 and 70.
While roller 68 preferably rotates about a fixed axis, roller 70 is mounted for rotation onto an adjustable axle 78 which is supported by a support arm 80. Support arm 80 rotatably mounted at one end 81 thereof, about a fixed axis 82 and is Further supported, at another end 83 thereof, by a spring 84. It will be appreciated that the stronger the spring, the greater the pressure that is imposed by roller 70 onto roller 68.
As the carrier sheet as drawn between rollers 68 and 70, heat applied to the sheet from source 69 is effective, in combination with the pressure applied to the sheet by the rollers, to fuse and fix the developed image onto the sheet. According to the shown embodiment, the sheet is fed between the rollers such that the developed image, shown generally at 101, contacts the surface of roller 68. Although it is greatly to be preferred that layer 71 has a material composition that virtually eliminates offset while not giving rise to squashing, smudging or smearing of the developed image when used in a liquid toner process, there is provided, nonetheless, a stripper 85 for ensuring paper removal.
Thus, in accordance with an embodiment of the invention and with reference to FIGS. 1 and 2, an electrostatic imaging process includes the steps of generating a latent electrostatic image on photoconductor 4, developing the latent image with liquid toner from bath 18, transferring the developed image to carrier sheet 100 and fusing and fixing the transferred image on the substrate by heat and pressure applied thereto preferably by passing it between rollers 68 and 70.
With further reference to FIG. 2, there is also provided apparatus for wetting heated roller 68 with silicone oil, such as 350F. The shown wetting apparatus comprises a wetting roller 86 which is mounted onto an adjustable axle 88, roller 86 being operative to rotate together with heated roller 68. There is also provided a spring-retained arm 90 which maintains contact between wetting roller 86 and roller 68 by applying pressure onto axle 88 in the direction of roller 68.
Wetting roller 86 is kept moist by a liquid absorbing element 92 which communicates with an oil trough 94 and which is maintained in touching contact with roller 86. Element 92 may, for example, comprise a layer of velvet mounted on a support. Oil trough 94 is supplied with silicone oil to a depth that is sufficient to keep element 92 damp enough so as, to moisten wetting roller 86. Oil is provided to trough 94 from an external reservoir 96 and is pumped therefrom at a very slow rate, by means of a pump 98 and an entry conduit 102. Excess oil in trough 94 drains therefrom back into reservoir 96 via an outlet conduit 104.
Reference is now made to FIG. 3 in which there is schematically illustrated a flash fuser, referenced generally 150. Flash fuser 150 comprises a platen 152 along which carrier sheet 100 is conveyed, as indicated, For fusing and fixing a developed image, shown by shaded areas 154, onto sheet 100. A housing 156 encloses a flash lamp 158 which is energized by a suitable conventional power supply 160. The light energy emitted by the flash lamp 158 is absorbed by the image on carrier sheet 100, causing fusing of the image onto the carrier sheet.
It is a feature of the invention that substantial evaporation of the liquid carrier in the developed image and otherwise present on the sheet does not occur during fixing and fusing and at least a large portion of the liquid carrier has been found to remain in the sheet when selecting the carrier liquid and flash energy in accordance with the invention.
It will be appreciated by persons skilled in the art that other methods of thermal fusing may be used in place of flash fuser 150 and roll fuser 64 in accordance with the present invention.
A suitable toner solution for the process of the present invention may be prepared as follows. ELVAX II 5720 (Dupont) (1000 g.) and ISOPAR L (Exxon) (500 g.) are mixed together at a temperature of 90°±10° C. for 1 hour, using a Ross Double Planetary mixture. Carbon black (Mogul L (Cabot), 250 g.) and ISOPAR L (500 g.) are added, and mixing is continued for 1 hour. ISOPAR L (2000 g.), preheated to 110° C. is added and mixing is continued for a further 1 hour. The source of heat is withdrawn, while continuing mixing until the temperature has fallen to less than 40° C. Of the resultant mixture, 3050 g. are milled at a temperature of 40°±2°-3° C. for about 22 hours with ISOPAR L (4000 g.) in a Sweco M18 Vibratory Mill containing 0.5"alumina cylinders. The product is a 12.5% solids concentrate; a working dispersion is obtained by diluting with ISOPAR L to a 1.5% solids content. In the Examples which follow, the Savin 870 photocopier requires 1.5 kg. of this working solution, to which is added 7-8 ml. of 10% lecithin in ISOPAR L as charge director, while the Savin V45 photocopier requires 0.8 kg. of this working solution, to which is added 3.5-4 mi. of lecithin in ISOPAR L as charge director. Elvax II type 5720 solvates substantial amounts of ISPOAR L (and is thereby plasticized) at temperatures in the range of about 65° C. to 100° C. In the method of toner manufacture described above, a temperature of between 70° C. and 90° C. is used. The non-volatile portion of the toner solution has a viscosity of not less than 2×106 centipoise at a temperature of 122±1° C. in the absence of carrier liquid.
The invention will now be illustrated by the following non-limitative Examples.
A Savin V45 photocopier which was modified to incorporate at the fixing and fusing stage a hot roller system as described above at an optimum temperature of 120+10° C. for minimum offset, was operated with a substrate speed of about 314 mm./sec., with a pressure applied at each side of the pair of rollers of 6 kg., using the liquid toner prepared as above. The length of the nip was about 4-6 mm. Under these conditions the major part of the ISOPAR L in the toner image was retained therein, while fusing and fixing was achieved.
A Savin 870 photocopier, having its internal fuser rendered inoperative, was used to generate copies on paper using the liquid toner prepared as described hereinabove. The copies were then subjected to flash illumination of about 0.75 Joule/cm2 and 400 microsecond pulse duration. Under these conditions the major part of the ISOPAR L in the toner image was retained therein, while fusing and fixing was achieved.
It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove.
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|A process for image production containing the heat-and-pressure fixing of a still wet or moist toner image
|Title not available
|Title not available
|Citing Patent
|Filing date
|Publication date
|Sep 28, 1999
|Feb 27, 2001
|Xerox Corporation
|Method and apparatus for forming a uniform layer of liquid developer
|Nov 5, 2003
|Jun 6, 2007
|Fixation device and image formation device
|Nov 26, 2004
|Jul 9, 2008
|Reduced light scattering in projected images formed from electrographic toners
|U.S. Classification
|International Classification
|Cooperative Classification
|European Classification
|May 26, 1994
Owner name: INDIGO N.V., NETHERLANDS
Free format text: CHANGE OF NAME;ASSIGNOR:SPECTRUM SCIENCES B.V.;REEL/FRAME:006993/0994
Effective date: 19940331
|Aug 31, 1999
|Fee payment
Year of fee payment: 4
|Aug 12, 2003
|Fee payment
Year of fee payment: 8
|Sep 5, 2007
|Fee payment
Year of fee payment: 12
|Sep 10, 2007
|Maintenance fee reminder mailed
|Dec 9, 2011
Owner name: HEWLETT-PACKARD INDIGO B.V., NETHERLANDS
Free format text: CHANGE OF NAME;ASSIGNOR:INDIGO N.V.;REEL/FRAME:027354/0521
Effective date: 20020918


text:
|Publication number
|Publication type
|Application number
|Publication date
|May 21, 1991
|Filing date
|Jan 31, 1990
|Priority date
|Apr 12, 1988
|Fee status
|Publication number
|Daniel T. McBride, William H. Stewart, Jr.
|Original Assignee
|Milliken Research Corporation
|Export Citation
|BiBTeX, EndNote, RefMan
|Patent Citations (2), Referenced by (26), Classifications (13), Legal Events (3)
|External Links: USPTO, USPTO Assignment, Espacenet
This application is a continuation of application Ser. No. 399,361 filed on Aug. 28, 1989, and now abandoned, which was in-turn a continuation of application Ser. No. 180,406 filed on Apr. 12, 1988, and now abandoned.
This invention relates to an apparatus and process for generating patterns on textile substrates carrying unfixed liquid dyes. More particularly, this invention is directed to an apparatus and process for pattern dyeing textile substrates wherein at least one stream or jet of pressurized gas is directed at the surface of a textile substrate to which has been applied an undried and unfixed liquid dye in the form of a spray, and to the resulting products.
In one preferred embodiment, a textile substrate carrying an unfixed and undried liquid dye, which has been applied in a pattern configuration using one or more fine sprays of dye propelled onto the substrate by a first set of gas jets, is subjected to one or more jets of air from a second set of jets at relatively close range. The mechanical action of the impinging jets or streams from the second set of jets on the unfixed dye is sufficient to displace or remove, from the area of impact, dye which has not been adsorbed onto the surface of the constituent fibers, thereby removing or redistributing unfixed dye and causing the area of impact to have a significantly lower dye concentration in the area of jet impingement. This area, upon fixing of the dye, is therefore dyed a visually lighter or less saturated shade of the dye than the surrounding non-impacted area.
As used herein, the term liquid dye shall be used to mean dyes, inks, or the like comprised of soluble matter in a solvent, as well as dyes or marking materials comprised of insoluble matter in a liquid medium. The term substrate is intended to encompass a wide range of textile constructions, such as woven or knitted fabrics, and may include non-woven constructions. Both flat and pile-like fabrics have been successfully patterned using the teachings herein, and are intended to be included in the term textile substrate as well. Fabrics comprised of various synthetic yarn types may be used including, but not limited to, polyester, nylon, and acrylic yarns. It is believed any yarn type or fabric construction which allows some unfixed liquid dye to be redistributed or removed by the action of an impinging gas stream may be patterned using the teachings herein. As used herein, the term "momentum flux" is used to describe the relative concentration of momentum of the air stream (i.e., the product of air mass and air velocity) striking the substrate. By using momentum flux as a parameter, various other process variables such as gas pressure, gas stream velocity at impact, and gas stream cross-sectional area may be implicitly accommodated.
Many techniques are known to apply dye to a textile substrate for the purpose of patterning the surface of the substrate. Among the most common is the direct application of dye of the desired colors to a previously dyed or undyed substrate. This technique is known as direct printing. Perhaps the most widely used direct printing technique is screen printing, in which dye or ink is forced through a specially prepared screen onto the substrate. The screen has areas in which the mesh has been blocked. These areas, which remain impervious to the dye or ink, correspond to pattern areas on the substrate in which no ink or dye is desired. Another direct printing method is known as metered jet printing, in which dye is selectively applied to an untreated substrate surface by one or more streams of dye which are positioned to strike the substrate surface as the substrate moves through the dye streams. The streams may be either continuously flowing onto the substrate surface, or may be intermittently initiated or interrupted in a variety of ways in accordance with pattern data. This method, which may afford some flexibility in pattern configuration, often requires a complex arrangement of valves and dye discharge devices which are costly and may require careful or continuing adjustment.
A characteristic of either technique is the limitation of shade flexibility generally afforded by such techniques due to the practical need to use a separate dye mix for each desired shade, and the limited number of dye mixes usually available for each substrate pass.
Another printing technique is resist printing, wherein a resist chemical is first applied to a dyed or undyed substrate in a specified area. The resist chemical can contain a dye or pigment. After fixing the resist, the substrate surface may be applied with a dye which, due to the blocking effect of the resist, does not affect the areas under the resist. Because of the multiple steps required, this process is more costly than applying a single batch of dye directly to the substrate. Furthermore, the control of color intensity or shading must be accomplished through the use of carefully formulated resist chemicals. Generally, it is difficult to achieve even moderately fine gradations of shading with this technique.
Discharge printing is yet another printing technique wherein a previously dyed or undyed substrate is dyed overall with a background shade, after which a chemical agent is applied to the substrate to discharge or chemically reduce the color of the background shade and eliminate, at least partially, the background shade from that area of the substrate. The background dye mix can contain dyes resistant to reduction by the discharge agent. In areas containing such dyes, the background color will remain. In addition, the discharge mix can itself contain dyes which are intended to replace or re-dye areas from which the original background dye has been chemically reduced. This technique requires highly specialized and expensive dyes, and is difficult to control if fine or uniform shade gradations are to be reproduced dependably.
These methods all provide acceptable results under some circumstances, but all share shortcomings which have been overcome by embodiments of the invention disclosed herein. In particular, all the above-mentioned techniques require carefully controlled formulations of dye and/or dye modification agents to be effective, and further require that, for each desired color shade, a separate formulation of dye or dye modification agent be used, or that the residence time of the dye modification agent be carefully controlled. Each such formulation must be made up in advance, and must be loaded into the appropriate patterning equipment prior to the start of the patterning operation. Once under way, desired variations in the pattern or shading are limited to those possible with the existing mix of dyes and/or dye modification agents. In addition, all these conventional techniques are ill-suited to generate softly-defined patterns characterized by regular or random-appearing dyed areas having diffuse, unobtrusively blended perimeters and wide shade variations within the dyed areas.
The invention disclosed herein provides a method for dyeing a textile substrate with a variety of shade variations of a given background (which may be comprised of one or more colors arranged in a diffuse pattern), without the uncertainty associated with resist or discharge printing techniques, and without the inflexibility or complexity associated with certain direct printing techniques. Specifically, the invention provides a method in which a variety of patterns and shade variations may be reproducibly generated on a moving textile substrate by first selectively applying and subsequenty removing or redistributing, in a controlled, selective manner, the previously applied unfixed and undried liquid dye from the substrate to produce various color shades and patterns. In a preferred embodiment, the unfixed liquid dye is applied in a pattern configuration, using one or more streams or jets of gas (e.g., air) to generate a fine spray of liquid dye droplets and, at the same time, direct such spray onto selected areas of the substrate surface. The unfixed liquid dye is then further patterned by selective redistribution or removal of the dye by the impingement of an independent set of gas jets (e.g., air) in accordance with the teachings herein to produce a novel effect. This embodiment uses jets of gas to apply dye in a pattern and then uses different jets of gas to rearrange or remove, in a similar or a different pattern, some of the dye so applied.
In accordance with the invention, unfixed and undried liquid dye on a substrate surface may be applied by the use of an array of gas streams or jets which generate a spray of dye droplets in the direction of the substrate. The applied dye may then be removed or redistributed by one or more independent streams or jets of pressurized gas directed at close range onto selected areas of the substrate surface. It has been discovered that patterns which are particularly visually attractive may be produced by a two stage process in which the background color of the substrate is applied in a pattern configuration using a first array of gas jets (e.g., air jets) to spray the substrate with dye droplets (Stage 1), followed by rearrangement or removal of the dye, using a second array of gas jets (e.g., air jets) (Stage 2). The preferred gas for both Stage 1 and Stage 2 patterning is air at ambient temperature, although other gases may be used if desired. The dye application technique of Stage 1 is the subject of commonly assigned pending U.S. patent application Ser. No. 07/062,141, filed June 15, 1987.
One particular advantage of using this background generating technique is that the general diffuse character of the patterns forming the background is matched by the diffuse character of the patterning achieved by the dye rearrangement/removal technique. A second particular advantage of using this background generating technique is the opportunity it presents to control both the color application and color removal processes --which are both dependent upon the control of gas jets directed at the substrate surface--with a single computer-driven process control system, making it convenient to generate patterns in register using the Stage 1 and Stage 2 processes running in tandem.
In the Stage 1 dye application technique of this invention, one or more arrays of closely spaced streams of liquid dye or ink are normally directed into a collection trough; in a preferred embodiment, a diverting surface or lip is used to intercept the streams and channel the liquid dye into the collection trough. Each stream in a given array has associated with it a source of pressurized fluid, for example, air, which, on command, forms and directs an atomizing stream or jet of air on a path which brings the atomizing air stream into contact with the streams of liquid dye or ink, whereby the streams of ink or dye are transformed into a mist of variously sized droplets of ink or dye which are propelled, by the combined momentum of the liquid and air streams, in the direction of the substrate to be marked. By interrupting the streams of atomizing air in oscillatory fashion, thereby causing the air to contact the liquid in bursts of extremely short duration, and by superimposing upon such oscillatory pulsations relatively longer-term patterning instructions which control the number of such pulsations to be executed by each individual atomizing air stream in each sequence of oscillations, uniform reproduction of various solid color or multi-hued patterns is possible. By employing such controlled pulsations, as well as by varying the distance over which the resulting spray must travel to reach the substrate and/or adjusting the physical position of the diverting surface with respect to the liquid stream and air stream sources, and with respect to the substrate, it has been found that droplet size distribution and the degree of droplet dispersion can be carefully controlled, yielding intricate patterns possessing great subtlety, delicacy, and variety which may be produced with a high degree of repeatability. By providing for the non-simultaneous actuation of adjacent atomizing air streams along a given array, a wide variety of side-to-side (i.e., across the width of the substrate web) patterns may be produced. By providing for multiple arrays, multiple color combinations may be employed, or, if preferred, combinations of dye and bleach or dye resist or other dye modifying compositions may be used.
In operation, the continuous stream of liquid dye tends to produce some droplets which are substantially larger than the fine mist ordinarily associated with an atomization process such as is employed herein. For purposes herein, the term "microscopic fragmentation" shall be used to describe the process whereby the liquid dye is broken up into a relatively fine mist, i.e., where droplet average diameter is generally substantially smaller than about 0.1 or 0.2 millimeter. The term "macroscopic fragmentation" shall be used to describe the process whereby the liquid dye is broken up into droplets having an average diameter on the order of about 0.1 or 0.2 millimeter, or larger.
It is believed that as the continuous stream of dye is interrupted by the advancing stream of air, the dye stream is atomized in the region of the stream directly in line with the advancing wave front of pressurized air, which results in microscopic fragmentation of the dye. That portion of the dye stream immediately above or below this in-line region remains coherent, but tends to become entrained in the periphery of the passing air stream and tends to separate into relatively large droplets and irregularly shaped spatters of dye (i.e., it undergoes macroscopic fragmentation) which are propelled toward the substrate.
In the following discussion, air at ambient temperature is assumed to be the gas of choice, with the understanding that other gases may be used as desired. By controlling the various parameters associated with the delivery of dye and air onto the substrate, a variety of shade variations may be produced, each shade being represented by a given reduced quantity per surface area of the liquid dye on the fabric surface. Where only a relatively small amount of unfixed dye has been removed over a given area by the impinging air stream, the resulting shade will be relatively close to the background color generated by the fully concentrated dye. Removing a relatively larger amount of dye from the area will result in a more "diluted" color or tone being generated, as viewed against the fully concentrated background level of unfixed dye. The resulting color may be a blend of the unfixed background dye color and the color of the substrate prior to the application of the unfixed dye. It is therefore possible to obtain a wide variety of multi-color effects based upon the blending of the underlying substrate color and various concentrations of the unfixed dye.
Where multiple colors are desired, the prompt application of a second liquid dye, as by spraying or other non-smearing means, to a substrate surface still wet from an initial application of dye results in the second color coating on the surface being relatively easy to remove using the teachings herein. It is believed that a substantial amount of the first or base layer of applied dye is adsorbed onto the fiber surfaces and becomes relatively securely attached thereto, even though unfixed. Subsequent applications of dye must look to areas of the fiber surface not yet occupied by a component of the first dye to find an adsorption site, or, finding no adsorption site, must occupy the interstitial voids between adjacent fibers or yarns. This results in the second dye having a relatively low and/or weak adsorption level, and permits substantial quantities of the second dye to be more readily removed or redistributed in accordance with the teachings described herein.
A special advantage of this invention is that the chosen shade variations may be modified while the substrate is being patterned--no prior preparation in the nature of formulating special dyes or other chemicals, or loading the patterning device with such dyes or chemicals, is required. Additionally, the process may be implemented using the computer controlled apparatus disclosed herein. As aided by such computer controlled apparatus, the invention may provide the following practical advantages:
(1) shade and pattern changes may be made at any time during the patterning process;
(2) variations in both shade and pattern may be made in carefully controlled and repeatable increments;
(3) computer generated patterns may be easily stored for reuse at any time;
(4) complex patterns involving pattern changes across the full width or length of the substrate may be easily accomplished, and may be reproduced on demand;
(5) where a sprayed-on background pattern as taught herein is used, the air jets used to redistribute or remove the unfixed dye may be directed in registration with the background pattern, since both air jet patterning processes may be computer controlled and may be performed at fixed positions along the substrate path.
Further features and advantages of this invention will be made evident by the following detailed description, when read in conjunction with the accompanying drawings, in which:
FIG. 1 schematically depicts an elevation view of an apparatus embodying the invention which may be used to generate a patterned background on a non-porous substrate which is further patterned by dye redistribution or removal;
FIG. 2 schematically depicts the apparatus of FIG. 1 adapted for use with a porous substrate;
FIG. 3 shows, in schematic form, a dye spray generator array of the type depicted at 300 in FIGS. 1 and 2, and the associated dye and gas handling apparatus;
FIG. 4 depicts, in a cross section taken along a vertical plane perpendicular to the longitudinal axis of array 300 and bisecting a dye pipe 330, a side view of the spray generator of FIG. 3;
FIG. 5 depicts a plan view of a portion of the array 300 shown in FIG. 3, as seen along line V--V of FIG. 4;
FIG. 6 depicts a section view of a portion of a spray generator illustrating one position of dye nozzle 332 of FIG. 4, as seen along line VI--VI of FIG. 5;
FIG. 7 is a view similar to FIG. 6, showing nozzle 332 in a different position;
FIG. 8 depicts a portion of the array 300 as seen along lines VIII--VIII of FIG. 6;
FIG. 9 is a section view, taken along line IX--IX of FIG. 8;
FIG. 10 is a section view taken along line X--X of FIG. 9, depicting the "V"-shaped notches useful in aligning the intersecting gas and dye streams;
FIG. 11 schematically depicts the Stage 2 patterning portion of the apparatus of FIG. 1, wherein the jet is directed against a backing member;
FIG. 12 schematically depicts the Stage 2 patterning portion of the apparatus of FIG. 2, wherein the jet penetrates the substrate and no directly opposing backing member is used;
FIG. 13 is a frontal view (i.e., as seen generally from the substrate surface) of the jet array of FIGS. 11 and 12;
FIG. 14 is a sectional view, taken along line XIV--XIV, of the array of FIG. 13;
FIG. 15 is a photomicrograph (1.15 X) showing the face of the patterned knitted fabric of Example 1;
FIG. 16 is a photomicrograph (10 X) showing, in cross-section, the fabric of Example 1; and
FIG. 17 is a plot showing the effect of increasing momentum flux on percentage of liquid dye removed.
Depicted in FIGS. 1 and 2, respectively, are alternative apparatus configurations for treating textile substrates in a first set of gas jets (at 300) are used to apply a spray of liquid dye onto the substrate (Stage 1), and a second set of gas jets (at 100) are used to pattern the substrate by removing or rearranging the sprayed-on dye (Stage 2). In the apparatus configuration of FIG. 1, the gas jets 100 are intended to be reflected from the textile structure and the underlying backing member almost exclusively (as shown in FIG. 11), while in FIG. 2 the gas jets 100 are intended primarily to pass through the substrate, but with some of the gas being reflected by the yarns comprising the fabric substrate (as shown in FIG. 12). As configured, the apparatus of FIGS. 1 and 2 provide for either continuous pad dyeing, via the conventional pad dyeing arrangement depicted at 180 and comprised of driven roll 164, dye bath 178, and opposed driven nip rolls 168,170, or the gas jet-generated spray dyeing, via the arrangement depicted at 300, which arrangement is discussed in more detail below. The user may elect, by appropriately configuring the path of the substrate web within the apparatus, to generate a solid background via the pad dyeing arrangement or generate a solid or patterned background using the spray dyeing arrangement.
Referring more specifically to the Figures, FIGS. 1 and 2 show, diagrammatically, an overall side elevation view of apparatus suitable for patterning a web of moving substrate material using the Stage 1 and Stage 2 patterning processes in tandem. The embodiment shown in FIG. 1 employs a backing member positioned directly opposite the dye redistribution/removal array 100, as generally shown in FIGS. 1 and 3. This configuration is generally preferred if a relatively gas-impervious substrate is used, but may be used with other substrates as well. Where the gas jet from array 100 is intended to pass through the substrate, the substrate support arrangement generally shown in FIGS. 2 and 4 may be substituted in the apparatus of FIG. 1, using rolls 191,193 positioned adjacent to the region of stream impact, as shown in FIG. 2.
Substrate 12 is supplied from any suitable source, e.g., roll 10, and is drawn over roll 150 and under roll 152 and valve house 250 to roll 156 which rotates in bearings fixed to platform 216. Substrate 12 is then directed into the interior of rolling frame 218, which is supported on wheels 212 and which may be moved along track 214 to adjust the distance between frame 218 and valve house 250, and, correspondingly, between arrays 300 and the surface of substrate 12. This permits easy and immediate observation of the effects of changing the spacing between valve house 250 (and the associated arrays 300 of spray generators) and the face of substrate 12. Substrate 12 is directed around roll group 230 and rolls 234,236 and through driven nip rolls 188,190, and is then presented, in a preferred embodiment, in a substantially vertical orientation to the multiple arrays 300 of spray generators mounted on the face of valve house 250. As shown in FIGS. 1 and 2, in a preferred embodiment, the substrate 12 may be separated from an appropriate backing member 220, which may be comprised of plastic or other dye-impervious material, by spacers 222,224 positioned along the top and bottom edges of backing member 220 above and below the level of the spray generator arrays 300, thereby assuring no contact between the back of substrate 12 and the backing member 220. This prevents unwanted smearing on the back of the fabric and prevents excessive saturation or accumulation of dye visible on the face of the fabric. In a particularly preferred embodiment, lower spacer 222 may be in the form of a trough-like collector which can serve to collect the sprayed liquid dye which may pass through substrate 12 and collect on backing member 220. Substrate 12 is then directed over backing roll 192 and over tension-generating roll 194, which may have a surface covered with rubber or the like and which may be overdriven to assure that substrate 12 is relatively taut in the region adjacent to arrays 300. As shown, substrate 12 may then be guided to an appropriate dye fixation means 50 or other post treatment processor. If desired, photoelectric cells may be used to determine the elevation of the catenary formed by substrate 12 between rolls 194 and 196, and thereby adjust the speed of the drive motor(s) associated with nip rolls 188,190 and roll 194.
FIGS. 3 through 10 collectively illustrate a preferred embodiment of the spray generator of the type depicted at 300 in FIGS. 1 and 2. FIG. 4 depicts a partial cross-section view along a vertical plane perpendicular to the longitudinal axis of array 300. The elongate array 300 is comprised of a plurality of individual spray generators, each comprised of a dye pipe 330 and nozzle 332 through which a liquid dye, ink, or other marking material may be pumped, and a dispersing aperture 340 and associated surround 342, through which a relatively high pressure dispersing fluid, for example, air or other gas, may be propelled. For purpose of discussion herein, air at room temperature shall be assumed to be the dispersion fluid. The individual spray generators are mounted in alignment, with an adjacent spacing appropriate to the degree of definition desired. It is believed adjacent lateral spacings of between about 0.2 inch and 1.0 inch, measured from the centerlines of adjacent dispersing apertures 340 along array 300, may be used with good results. Spacings outside this range may be used if, for example, minimal overlap between adjacent spray patterns on the substrate is desired.
As depicted in FIG. 3, further associated with each generator is an electronically controlled valve 260 which is interposed in the pressurized air lines 264 and 266 which serve to supply the apertures 340 with pressurized air from manifold 270, which in turn is suitably connected, via regulator 276 and filter 274, to a source 272 of pressurized air. Valves 260 are, in a preferred embodiment, of the electrically actuated pneumatic type such as those distributed by the Lee Company of Westbrook, Conn. Associated with each dye pipe 330 is dye supply line 288 which extends from dye manifold 280, which is fed, via pressurizing pump 284 and filter 286 and associated conduits, from dye reservoir 282. Dye conduits 292 and 294 supply reservoir 282 with excess dye from manifold 280 and captured dye expelled by nozzles 332 (FIG. 4) into containment trough 362, thus forming, in a preferred embodiment, a recirculating dye system.
As shown in FIG. 10, elongated array frame 310 is constructed with a series of parallel "V"-shaped notches or grooves 302, 304, spaced along its length, in precisely opposed pairs along the top and bottom of frame 310 at intervals corresponding to the desired lateral spacing between adjacent dye pipes 330 and air conduits 314. Air conduits 314 may then be placed within "V"-shaped grooves 304 directly opposite corresponding dye pipes 330, and attached to respective air lines 266 (FIG. 4). By aligning grooves 302, intended to accommodate dye pipes 330, and corresponding grooves 304, intended to accommodate air conduits 314, the intersecting alignment of the corresponding dye and air streams necessary for maximum dye stream fragmentation may be more easily controlled. As shown in FIG. 9, dye pipe positioning plate 370 and air conduit positioning plate 320, respectively secured to frame 310 via laterally spaced bolts 380 and 385, maintain dye pipes 330 and air conduits 314 within their respective "V"-shaped grooves. Due to the self-centering nature of the "V"-shaped grooves 302, 304 (as compared with other possible groove cross-section shapes), no additional stream alignment technique is needed, provided grooves 302 and 304 have been placed directly opposite one another. The array 300, comprising frame 310 and positioning plates 370,320, is suitably attached, via rigid member 290 and mounting bolts 384, to the front face 252 of valve house 200 (FIG. 4).
While the angle between dye pipes 330 and air conduits 314 is depicted as approximately thirty degrees, this merely represents one preferred embodiment. Angles less than and greater than that shown may be advantageously employed under some conditions, so long as the resulting pressurized dye stream is not sent on a trajectory from nozzle 332 which, in the absence of an interacting burst or stream of air, results in continuous contact with the substrate. Air conduit 314 is fitted with a tapered coupling so that air at pressures of 60 p.s.i.g. or more may be transferred to replaceable port aperture 340 from supply line 266 (of which two are depicted in FIG. 4, to indicate a suggested arrangement for accommodating closely adjacent lines 266), which in turn is connected to valves 260 via fittings 254 in front wall 252 of valve house 250. In one embodiment, air valves 260 are situated in close proximity to fittings 254, and may be arranged on a pneumatic circuit board analogous to an electronic circuit board. Such pneumatic circuit board or "valve card" may be equipped with suitable mating fittings so that a valve card carrying a plurality of individual air valves for individually controlling a corresponding plurality of individual spray generators may be merely plugged into corresponding fittings 254 mounted on the inside of front wall 252. In such embodiment, a suitable number of valves 260 may be individually mounted on one such a valve card, with multiple valve cards mounted in adjacent fashion to provide control along the length of the entire array 300.
Associated with aperture 340 is shroud or surround 342, through which nozzle 332 may extend via surround port 344. Surround 342 tends to maintain the high velocity of the dispersing medium jet formed by aperture 340 and to focus the jet in the direction of the substrate. Operation without surround 342 or a similar confining enclosure results in a process which generates an undesirable cloud or mist of dye which is difficult to control in terms of placement, degree of mixing of adjacent sprays, etc.
Nozzle 332, supplied with slightly pressurized dye via dye supply line 288 and dye supply manifold 280, is associated with pipe 330 which fits within "V"-shaped groove 302. The relative position of nozzle 330 within surround 342 may be changed, as is shown in FIGS. 6 and 7, by moving pipe 330 within groove 302 and locking pipe 330 in the desired position by means of set screw 380 and the clamping action of positioning plate 370. This adjustment has been found to alter the character of the spray by changing the radial distance from the axis of the air jet, and therefore the character (e.g., velocity, pressure, etc.) of the region within the air jet at which the dye is ejected from the protected confines of nozzle 332. Although it is contemplated that nozzle 332 may be located substantially above the axis of aperture 340, it is preferred that nozzle 332 be positioned within surround 342. In a preferred embodiment, the tip of nozzle 332 is positioned at most a short radial distance from the axis of aperture 340 so that, whenever the air stream associated with aperture 340 is actuated, the liquid emanating from nozzle 332 is immediately acted upon by the jet and does not have the opportunity to form a defined, coherent stream except during interruptions in the flow of air from aperture 340.
Perpendicular to the longitudinal axis of dye nozzle 332 and, in the embodiment shown in the Figures, generally situated opposite aperture 340 and parallel to array 300, is a diverting lip or surface 360. Surface 360 is mounted so that dye exiting from nozzle 332 will, in the absence of a disturbing air stream from aperture 340, form a stream which travels in a trajectory which terminates on diverting surface 360 and flows into an associated containment trough 362, as shown in FIG. 4. From trough 362, the dye may be pumped, via dye basin 364 and conduit 294, either back to dye reservoir 282 for re-use or to a suitable waste receptacle. In the preferred embodiment shown, surface 360 may be mounted inside trough 362 to extend upwardly therefrom, and is preferably mounted via a suitable adjusting means so that the degree to which surface 360 extends into or beyond the path of the dye stream, as well as the relative spacing and alignment of the surface 360 with respect to nozzles 332 and surrounds 342 in array 300, may be adjusted. It is contemplated that surface 360 may be relatively rigid or, alternatively, may be a relatively thin, flexible blade which is given rigidity by clamping each end of the blade and applying suitable tension along the length of the blade.
Where the dye stream is squarely impacted by the air stream, microscopic fragmentation takes place, and a relatively fine mist is generated and propelled in the direction of the substrate. A portion of such mist usually strikes diverting surface 360 and coalesces there as liquid dye. As the air stream reaches the region of the diverting surface, a portion of the air stream tends to impinge on the inside of the surface and tends to push any dye which may be there, either as a result of coalescing mist or of having been the target of the uninterrupted dye stream, away from the area of impingement. Some dye is pushed downwardly into the collection trough 362, but some is pushed upwardly, toward the edge of diverting surface 360, and is ultimately pushed over the edge and is carried by the air stream toward the substrate, in the form of larger droplets and irregularly shaped spatters (i.e., the product of macroscopic fragmentation).
When actuated, valves 260 associated with air supply lines 266 prevent air from passing through port aperture 340. As a result, ink is permitted to stream from nozzle 332 to diverting surface 360 without interruption, as shown in FIG. 4, where it is dissipated and collected in containment trough 362 and drip basin 364 and, ultimately, pumped back to dye supply manifold 282 in pressurized form or discarded.
FIGS. 6 and 7 depict the dye applicator in operation where pulses of air, generated by the rapid actuation and deactuation of valves 260, are being supplied to aperture 340. Pressurized air entering conduit 314 and passing through aperture 340 forms a jet which interacts with dye which is continuously supplied from the tip of nozzle 332. The resulting spray of dye droplets is directed onto the surface of substrate 12. In the embodiment shown on FIG. 6, the tip of nozzle 332 is positioned within the region occupied by the jet, so that the dye is acted upon by the jet immediately upon its exit from nozzle 332. This position tends to suppress the formation of the relatively larger spatters, flecks, and blotches associated with macroscopic fragmentation, and tends to encourage the fine mist formation associated with microscopic fragmentation.
As a result of the interaction of the stream of relatively low pressure dye (typically about 0.2 to about 4 p.s.i.g.) with the stream or jet of relatively high pressure air (typically about 5 to about 60 p.s.i.g.) within or in front of surround 342, the stream of dye is dramatically disrupted, and is usually atomized to some degree. In a preferred embodiment, the ratio of dispersing material pressure (e.g., air) to marking material pressure (e.g., dye) will generally fall within a range of about 5 to about 60, but may fall outside this range under certain conditions. For example, if high viscosity marking materials are used, higher than usual dispersing material pressures may be desirable, causing the above ratio to exceed 60.
A variety of droplet sizes and mist is produced, which are generally propelled in the direction of the surface of moving substrate web 12. Web 12 may be positioned typically from about two to about twelve inches from the tips of nozzles 332. By varying factors such as the respective pressures of the dye and air streams, the viscosity of the dye, and the degree to which nozzle 332 protrudes through surround port 344 and intrudes into the air stream flowing from aperture 340, a wide variety of visually attractive commercial products may be generated in a reproducible manner. Other factors which may be varied to change the visual effect produced include the degree to which the diverting surface 360 is made to extend into the area in which the dye spray is generated, the distance between nozzle 332 and diverting surface 360, and the distance between nozzle 332 and substrate 12.
The adjacent spacing of the individual nozzles 332 and apertures 340 comprising the plurality of spray generators spaced along the longitudinal axis of array 300 is generally fixed for a given apparatus in order to maintain proper alignment. This spacing is preferably such that, for a given nozzle-to-substrate distance, the spray patterns from immediately adjacent spray generators have substantially overlapping trajectories, allowing for the overlapping and mixing of the spray patterns throughout a significant percentage of the spray path between nozzles 132 and the surface of substrate 10, as depicted in FIG. 8. In a preferred embodiment, the included angle of the spray pattern may be on the order of about 25 to about 50 degrees, the adjacent spacing may be about 0.3 to about 0.6 inch, and the nozzle-to-substrate distance may be from about four to about eight inches. Under such conditions, the overlap and mixing of sprays generated not only from immediately adjacent nozzles 332, but from nozzles 332 spaced two or more nozzle spacings away, has been observed. It is believed such substantial mixing and overlapping of the individual spray patterns while the dye sprays are moving toward the substrate contributes greatly to the blending and diffusion which characterizes the diffuse character of patterns generated by this process.
In a preferred embodiment, the valves 260 controlling the flow of air to aperture 340 are actuated by means of computer control, which permits each of the individual dye streams to be selectively interrupted in response to externally supplied pattern data, thereby providing the capability of reproducing complex side-to-side patterns extending across the width of substrate 12. This computer control may be associated with the computer control used in the Stage 2 dye removal/rearrangement patterning operation which follows this patterning operation. Computer control may also be used to accommodate variations in dye pick-up or dye deposition requirements among different types of substrates, as well as variations in the speed of the substrate as it is drawn through the apparatus. This may be achieved in a manner similar to that disclosed in U.S. Pat. Nos. 3,894,413; 3,969,779; or 4,033,154, or by other appropriate means.
Following application of liquid dye to the substrate 12, the web is directed over one or more rolls positioned opposite impinging jet array 100. In the embodiments shown in FIGS. 1, 2, and 11 through 14, jet array 100 is comprised of a series of parallel, closely spaced tubes 110 (FIG. 13) of relatively small diameter directed at the surface of substrate 12. Each tube is connected to a respective flexible conduit 112 through which pressurized gas is supplied. The outlets of tubes 110 are arranged at a uniform distance from the surface of substrate 12 within array alignment plate 122, shown in cross-section in FIG. 14, which holds individual tubes 110 in rigid alignment as discussed hereinbelow.
As shown in more detail in FIGS. 13 and 14, tubes 110 are arranged in a linear array with minimal spacing between adjacent tubes. One side of each tube 110 is positioned within an individual "V" shaped notch or groove along the lip of an alignment plate 122 which is fastened securely to array bar 134. Opposite plate 122 is positioned pressure plate 124, which contacts the side of each tube 110 protruding from the confines of each "V" shaped notch or groove in alignment plate 122. The action of pressure plate 124 and adjusting bolt 126 urging tubes 110 snugly into their respective notches in alignment plate 122 allows for rigid, repeatable alignment of the outlets of tubes 110 above the surface of substrate 12.
As depicted in FIG. 14, each tube 110 is bent to facilitate side-by-side tube arrangement having minimal adjacent tube spacing measured along the axis of alignment plate 122. Tubes 110 each pass through a drilled passage in support plate 128, which, as shown, is attached to alignment plate 122 via attachment bolts 130. The drilled passages of FIGS. 13 and 14 are depicted in a three hole, quasi-sinusoidal configuration; other configurations may be used. For ease of fabrication, assembly, and maintenance, alignment plate 122, pressure plate 124, and support plate 128 may each be configured in relatively short, abutting sections which are attached to array bar 134 extending across the width of substrate 12. As depicted, array bar 134 is adjustably attached to articulated linkage 140, whereby the array may be adjustably positioned with respect to substrate 12 for patterning, changing substrates, cleaning of the array, etc.
Tubes 110 are each attached to individual conduits 112 through which is supplied pressurized gas of the desired kind, e.g., air at ambient temperature. In a preferred embodiment, each conduit 112 is associated with an individual valve, not shown, which is electrically or pneumatically controlled by externally supplied patterning information, thereby allowing the pressurized gas to flow through any individual conduit 112 and associated tube 110 and onto the substrate 12 only in response to pattern information. The individual valves as well as the source of pattern information (which may be a read-only memory associated with an appropriate computer) may be located in housing 70, as shown in FIGS. 1 and 2. To facilitate positioning array 100 close to the substrate for patterning but away from the substrate for maintenance, changing substrates, etc., housing 70, to which array 100 is attached in the Figures, may be mounted on sliding carriage 72.
Looking now in detail at the apparatus of FIGS. 1 and 11, substrate 12, which may have a pile face, as depicted, or which may be a flat fabric, is directed through an approximate 90� wrap angle around single support roll 30. In a preferred embodiment, roll 30 is smooth and solid, but a foraminous or contoured roll surface may be employed if special patterning effects are desired. Wrap angles other than 90� may be used as desired. However, it is preferred that the substrate to be patterned in this configuration be in contact with the support roll 30 at the point where the jets contact the substrate. This minimizes any tendency of the substrate to oscillate or flap in response to the jet impingement. It also assures maximum reflection of gas and liquid dye from the fabric surface and underlying support surface where the principal mechanism of dye removal is intended to be dye droplets ejected from the face of the substrate. This is the configuration of choice where the substrate construction used is relatively impervious to the gas jets of the kind contemplated herein, as, for example, where back-coated substrates are used, but such configuration may be employed, using a solid backing roll, for any type fabric to produce a characteristic effect.
Depending upon the fabric construction, the gas jet may penetrate the substrate only to a depth of a fraction of a yarn diameter, or may penetrate the substrate until encountering an impenetrable barrier such as a back coating or the surface of the backing roll. The jet is then redirected outwardly from the barrier and substrate. In all cases, the impact of the jet on the substrate causes redistribution of the liquid dye held by the substrate in the area of impact. Specifically, the liquid dye is "squeezed" from the substrate within the area of impact and accumulates as a drop or globule on the substrate surface, and is ultimately ejected by the momentum of the outwardly redirected jet. Catch basin 92 may be used to collect and, if desired, recycle liquid dye ejected from the substrate.
The alternative apparatus configuration of FIGS. 2 and 12 is generally more suited to substrates which the gas jets will penetrate readily, and for which a principal dye removal mechanism will be via dye droplets blown entirely through the substrate and leaving the substrate from the back of the fabric. As shown in detail in FIG. 12, the substrate is positioned opposite jet array 100 via a pair of spaced rolls 34,36 which leave the fabric unsupported, except for web tension, in the region of jet impact. This unimpeded path through the substrate, when used with an appropriately chosen substrate construction (i.e., one which is readily penetrated by gas jets of the kind contemplated herein) results in a substantial part of the impinging gas passing through the substrate, pushing or carrying droplets of liquid dye with it in the direction of catch basin 96. Because some dye droplets also emerge from the face of substrate 12 due to reflective interactions with the individual yarns comprising substrate 12, a second catch basin 94 placed below the face of the substrate may be employed. If recycling of the dye is desired, catch basins 94,96 may be associated with dye recycling filters, pumps, etc., not shown.
In the embodiment of FIGS. 1 and 11, as well as the embodiment of FIGS. 2 and 12, the angle at which the gas jets are directed at the substrate (the impingement angle) may be adjusted over a wide range. It has been found that, although significant effects may be observed at any angle which allows the gas streams to impinge the fabric, a preferred attack angle lies within the range of 0�-60�, as measured from the perpendicular of the substrate at the region of impact and as indicated by the angle θ in FIG. 11. The measurement of the impingement angle in the embodiment of FIG. 12 is similar. Impingement angles within the range of about 25� to about 45�, and particularly within the range of about 30� to about 40�, are especially preferred. While the preferred relative direction of substrate travel is as indicated in the Figures (i.e., jets directed against the direction of substrate travel), operation in the reverse direction may be desirable under some circumstances. When patterning a pile fabric, it has also been found generally advantageous, although not necessary, to orient the pile so that the action of the jets tends to lay the pile down further in the same direction, rather than raising the pile.
The generation of uniform background shades upon which patterns may be imparted by jet array 100 may be achieved using the spray dyeing arrangement depicted at 300 in FIGS. 1 and 2, or by other appropriate means known in the art.
Dyes or other marking materials having a wide variety of flow characteristics may be used with the Stage 1 dyeing technique described herein; generally speaking, higher viscosity liquids tend to increase the degree of macroscopic fragmentation which occurs, while lower viscosity liquids tend to increase the degree of observed microscopic fragmentation. Various thickeners, thixotropic or pseudoplastic agents, surface tension modifiers, and the like have been used with interesting results. For example, use of agents such as guar gum which cause the liquid dye to become "stringy" causes the resulting pattern of dye on the substrate to contain a random line segment pattern element which somewhat resembles portions of a spider web, and which contains blobs or nodes of dye positioned at various intervals along the length of the line segments.
FIGS. 1 and 2 both depict a treatment zone 50 following the gas jet patterning station described hereinabove. It is contemplated that treatment zone 50 may be used for drying and fixing the pattern dyed substrate, as appropriate, immediately following the patterning step and prior to storage of the pattern dyed fabric on take-up roll 60. The nature of this treatment zone is dependent upon the composition of the substrate. As depicted, driven rolls 52,54 are used to assist in drawing the substrate web through the patterning station and treatment zone 50 and onto take-up roll 60. If desired, of course, the patterned fabric containing unfixed liquid dye may be subjected to other treatments prior to drying and/or fixing.
The process and apparatus disclosed herein has been used to pattern or color a variety of commercially available textile substrates, and has resulted in many visually distinctive effects. The following illustrative example is intended to demonstrate the embodiment of the invention wherein the substrate was dyed using the apparatus and process of FIGS. 1 and 3 through 11, and is not intended to be limiting in any way.
An eleven ounce per square yard warp knit, 100 percent polyester, pile upholstery fabric having a 3/32 inch pile height, was first conventionally padded to 80 percent of weight of the dry fabric with a light brown disperse dye solution. The fabric was then immediately passed through a spray dye application treatment similar to that depicted in FIGS. 3 through 10, where a vertical stripe pattern of burgundy, light blue and green disperse dye solution was overdyed at approximately 60 percent wet pick up, based on the weight of the dry fabric, using the spray dye application technique disclosed above. Dye flowing at the rate of 28 grams/minute per jet was sprayed onto the substrate through nozzles having an inside diameter of 0.019 inch and a jet-to-jet lateral spacing along the array of 0.4 inch. Air jet supply pressure was 42 p.s.i.g., and air jet aperture inside diameter was 0.040 inch. Substrate speed was five yards per minute, and substrate-to-jet spacing was approximately 5.25 inches.
The fabric was then passed through the dye rearrangement/removal treatment, similar to that depicted in FIGS. 1 and 11 , comprised of a plurality of air orifices mounted in a linear array having a lateral spacing of 25 orifices/inch and spaced 1/32 inch from the face of fabric, where air at 35 p.s.i.g. supply pressure removed dye in pattern form. The fabric was then conventionally thermosol dyed at 380� F. for three minutes, washed, and dried. The resultant pattern is depicted in FIG. 15 (1.15 X). The areas impacted by the dye rearranging/removing air jets are shown as the lighter, leaf-shaped areas of FIG. 15. FIG. 16 (10 X) shows the fabric in cross section. The right side of FIG. 16 depicts an area of the resultant fabric that was overdyed in the spray dye treatment zone only. The left side of FIG. 16 depicts an area of the resultant fabric corresponding to a leaf-shaped area, which was overdyed in the spray dye treatment zone and where some of the dye was subsequently removed by the action of the rearranging/removing jets. Yarns on this left side therefore carry a lower concentration of the sprayed dye than do yarns on the right side. The right and left sides therefore exhibit different colors, due to the different relative concentrations of the (same) dye which resides on each side.
Many factors influence the degree to which liquid dye may be displaced or removed from a substrate in accordance with the teachings of this invention. For example, gas stream velocity, relative substrate speed, and orifice-to-substrate spacing have been found to influence appreciably the extent to which the impinging gas stream has sufficient energy to move or entrain a visually significant quantity of dye. The graph of FIG. 17 attempts to approximate the functional relationship between momentum flux and the percent of liquid dye removed from a dye-wet substrate of the type contemplated in the examples, for the case of a single jet. In the graph of FIG. 17, it may be seen that increasing the momentum flux as by increasing gas stream velocity or decreasing the substrate-to-jet spacing, generally results in increased dye removal.
It should be understood that variations and modifications to the above teachings may be made without departing from the substance of the invention as described.
|Cited Patent
|Filing date
|Publication date
|Aug 28, 1989
|Jun 19, 1990
|Milliken Research Corporation
|Method for patterning dyed substrates
|Mar 8, 1974
|Sep 11, 1975
|Hoechst Ag
|Verfahren und vorrichtung zum kombinierten, kontinuierlichen faerben und bedrucken von garnen zwecks herstellung von space-dyeing-effekten
|Citing Patent
|Filing date
|Publication date
|Mar 2, 1990
|Jul 7, 1992
|Milliken Research Corporation
|System for the real-time scheduling and loading of look-up tables for a patterning device
|Apr 24, 1995
|Sep 24, 1996
|Machine for dyeing textile yarns
|Jul 1, 1997
|Apr 20, 1999
|International Dyeing Equipment, Inc.
|Jet dyeing machine
|Jun 23, 2003
|Apr 25, 2006
|Sara Lee Corporation
|Spray dyeing of garments
|Jul 9, 2004
|Nov 7, 2006
|Milliken & Company
|Apparatus and method for forming multi-colored yarn
|Sep 21, 2010
|Hbi Branded Apparel Enterprises, Llc
|Processes for spray dyeing fabrics
|Apr 26, 2011
|Hbi Branded Apparel Enterprises, Llc
|Compositions for spray dyeing cellulosic fabrics
|Apr 26, 2011
|Hbi Branded Apparel Enterprises, Llc
|Composition for dyeing of cellulosic fabric
|Jan 24, 2006
|Apr 26, 2011
|Hbi Branded Apparel Enterprises, Llc
|Composition for dyeing of cellulosic fabric
|Mar 26, 2013
|Hbi Branded Apparel Enterprises, Llc
|Method for spray bleaching cellulosic fabrics
|Apr 5, 2011
|Oct 29, 2013
|Hbi Branded Apparel Enterprises, Llc
|Composition for dyeing of cellulosic fabric
|Apr 4, 2011
|Dec 3, 2013
|Hbi Branded Apparel Enterprises, Llc
|Compositions for spray dyeing of cellulosic fabrics
|Feb 16, 2009
|Aug 26, 2014
|Hbi Branded Apparel Enterprises, Llc
|System and method for spray dyeing fabrics
|Nov 5, 2014
|May 17, 2016
|Milliken & Company
|Apparatus and method for controlled application of liquid streams to a substrate
|Jun 23, 2003
|Jul 1, 2004
|Sara Lee Corporation
|Spray dyeing of garments
|Jul 9, 2004
|Dec 2, 2004
|Brown Robert S.
|Apparatus and method for forming multi-colored yarn
|Jun 4, 2004
|Dec 9, 2004
|Henry Shaw
|Method and device for applying several substances to a yarn
|Feb 16, 2006
|Jun 29, 2006
|Sara Lee Corporation
|Spray dyeing of garments
|Jan 24, 2006
|Nov 23, 2006
|Sara Lee Corporation
|Composition for dyeing of cellulosic fabric
|Mar 31, 2006
|Nov 30, 2006
|Sara Lee Corporation
|Processes for spray dyeing fabrics
|Mar 29, 2006
|Nov 30, 2006
|Michael Abbott
|Formers for spray dyeing garments
|Jan 23, 2007
|Aug 30, 2007
|Hbi Branded Apparel Enterprises, Llc.
|Composition for dyeing of cellulosic fabric
|Dec 8, 2008
|Jun 10, 2010
|May Ruth E
|Compositions for spray bleaching cellulosic fabrics
|Jul 28, 2011
|May Ruth E
|Composition for dyeing of cellulosic fabric
|Jul 28, 2011
|May Ruth E
|Compositions for spray dyeing of cellulosic fabrics
|Mar 15, 1996
|Sep 19, 1996
|Milliken Research Corporation
|Method and apparatus to selectively carve textile fabrics
|U.S. Classification
|International Classification
|Cooperative Classification
|European Classification
|May 26, 1994
|Fee payment
Year of fee payment: 4
|May 28, 1998
|Fee payment
Year of fee payment: 8
|May 21, 2002
|Fee payment
Year of fee payment: 12

subset: commoncrawl


text:
tax manager jobs near Houston, TX
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Weaver - Houston, TX
Are partnering together to locate a Tax Manager for the Houston, Texas location. State and local tax;...
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Responsible for managing tax reporting, tax planning, and compliance function. Experience in dealing with international tax issues such as US outbound tax...
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State and local tax; Assist with other tax projects as needed. Are partnering together to locate a Tax Senior Associate for the Houston, Texas location....
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And state individual income, gift tax, and estate tax returns. Prepare and review complex tax planning projections for individual and corporate estimated tax...
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TAX. Deloitte Tax LLP, Business Tax Services (BTS) professionals understand the intricacies of tax regulations and their relationships to business....
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Performs diversified accounting, auditing, and tax assignments under the direction of supervisor, manager, and principal....
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Identify and communicate accounting and auditing matters to managers and partners. KPMG auditors use a multidisciplinary approach to combine such technical...
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text:
Eurofase Lighting 12530-052
Three Light Down Lighting Pendant from the Dervish Collection
- Item # bci1702091
- Model # 12530-052
- Dervish Collection
$466.90, You Save 13%
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Leaves the Warehouse in 1 to 2 business days
Score 406 reward points with the purchase of this product!Learn More Here
Traditional / Classic Three Light Down Lighting Pendant from the Dervish Collection
Concentric curved panels form a drum shade - pieces are spaced giving the illusion that they are floating in alignment.
- Three light down lighting pendant
- Chrome finish available with Frosted White glass shade or Artstone shade or Mahogany shade
- Satin Nickel available with Frosted White glass shade
- Requires (3) 60w A19 Medium base bulbs (not included)
- Height: 5.5"
- Diameter: 15"
- Chain / Cord Length: 72"
- Voltage: 120V
Additional Eurofase Lighting Links
This product is listed under the following manufacturer number(s):
- Eurofase Lighting 12530-014 Chrome / Artstone
- Eurofase Lighting 12530-052 Chrome / Frosted White Glass
- Eurofase Lighting 12530-021 Chrome / Mahogany
- Eurofase Lighting 12530-045 Satin Nickel / Frosted White Glass
*Denotes a finish or option that has been discontinued.
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Whether you are installing the product yourself or hiring a professional, our installation ResourceCenter has everything you need to get your project done. Visit the Installation Resource Center to get started.
Eurofase Lighting Company Overview
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text:
Ronseal Perfect Finish Ultimate Protection Natural Cedar Decking Oil 2.5L
£15.60 per L
Ronseal Perfect Finish Ultimate Protection Natural Cedar Decking Oil 2.5L
£15.60 per L
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Product Details
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Revitalise and nourish your decking with this decking oil from Ronseal. Suitable for use on bare or previously oiled ridged or smooth hardwood and softwood decking, simply apply using a deck pad and leave for 24 hours to dry. Covers up to 8 m² per litre on average.
- Restores wood oils lost through weathering
- Prevents greying and splitting and resists mould and algae growth
- Lasts twice as long as standard decking oils
Features and benefits
This Perfect Finish Oil includes a Perfect Finish pad and pole, everything you need in one pack. It'll help you get the job done fast, without the backache. It nourishes deep into your wood to stop it drying out and protects much longer than standard decking oils.
- Colours, protects and waterproofs decking in one, saving you time and effort
- Scuff resistant formula
- Withstands foot traffic
- Resists cracking, peeling and blistering
- Rainproof in just 90 minutes
Technical specifications
|Perfect Finish Ultimate Protection
|Colour description
|Natural cedar
|Up to 8 m² per litre
|Drying time
|Recoat time
|Paint/Stain/Varnish base
|Touch dry time
|VOC description
|Deck pad
|For use on
|Bare or previously oiled ridged or smooth hardwood and softwood decking
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Please note that this item has additional safety or regulatory datasheets available. The product may have possible health and safety hazards covered in these documents. Refer to the container for full information and always follow the instructions.
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If you're painting on bare wood, plaster or metal surfaces, you'll get a better result if you use a primer first. It provides a surface which the paint can bond to and stops the paint being absorbed. Find out more what you need and for what surface.
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Finding the right combination of colours to match your home and personal taste is essential, but it can often feel like looking for a needle in a haystack.
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You can apply this hardwood garden furniture oil from the Ronseal Woodland Trust range to all quality hardwoods including teak, oak, mahogany and iroko, using a cloth, to colour and provide protection against weathering. It takes 2 hours to dry. Penetrates wood restoring the natural oils lost through weathering ...
Square profile newel section complete with spigot ready to connect to new or existing newel base High quality Oak that's ready to varnish or oil to enhance the natural character of this timber FSC Certified. (Forestry Stewardship Council) / Engineered and mnaufactured in the UK Made from responsibly sourced, ...
Square section newel base is designed to connect to any 90mm newel turning High quality Oak that's ready to varnish or oil to enhance the natural character of this timber FSC Certified (Forestry Stewardship Council) / Engineered and manufactured in the UK Made from responsibly sourced, Forest Friendly timber ...
You can apply this hardwood garden furniture oil from Ronseal to all quality hardwoods including teak, oak, mahogany and iroko, using a cloth, to provide protection against weathering. It takes 6 hours to dry and will cover up to 6 m² per litre on average. Penetrates wood restoring the natural ...


text:
Oregon Scientific Heart Rate Monitor Watch
This Heart Rate Monitor features "ONE TOUCH" Finger Sensor HRM.
- Specifications:
- Measures the heart rate and calories burned
- Time mode - display current time and date
- Daily alarm mode - daily alarm and hourly chime
- Chronograph stop watch mode
- Professional design in plastic sport case with PU strap
- Inside battery life: over 1 year under normal use
Product Details
- 0734811707819
- Manufacturer:
- Oregon Scientific
- Publication date:
- 12/05/2011
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Oregon Scientific Heart Rate Monitor Watch based on 0 ratings. 8 reviews.
I was thrown off from the product title that included 'Pedometer'. It's just a hear rate watch that can also estimate how many calories you've burned based on your heart rate it can monitor. While I'll keep the watch for this purpose, I was a little disappointed and felt a little mislead.
Misleading description----came as a "calorie counter", not a pedometer!
I returned this watch to a B&N store after trying it for a few days. It is not a pedometer (as advertised). It does not flash a bar showing your level of activity intensity (as it says it does in the directions that came with the watch). After working out you have to manually select the intensity level of your work out, then hold your finger on the pulse sensor to get a measurement of calories burned. Too much trouble! I think I'll spend a little more $ and get a watch that is easier to use and works as advertised.
VERY MISLEADING!! THIS IS NOT A PEDOMETER, IT is A HEART RATE MONITOR/CALORIE COUNTER. DO NOT BE FOOLED!! POOR RATING BECAUSE IT IS NOT THE ITEM I ORDERED.
This watch seems to be very well made ... except I (& we) were absolutely unable to get the pulse rate option to work ... which is the one thing I purchased it for.
In reviewing the functions of the watch I like what it is supposed to do. Yet it is a bit complicated to take advantage of the functions. I have had to refer to the instructions several times and still cannot get the full range of functions. It is also a stiff band. Still going to try to use it.
Purchased as a gift for grandson who is a high school sophomore track & field runner. Feedback from him so far has been positive. Proud Grandmother
Very disappointed...could notget it to work. Thought it would work as advertised. Will continue to try to get each of the programs ....